Checker Vision Sensors. Product Guide

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Gertrude Grant
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1 Checker Vision Sensors Product Guide

The Smart Vision Sensor Looking for the easiest, most affordable way to error-proof your manufacturing process?

machine builders. Today, Checker has a complete product family spanning from lower-resolution, extremely fast sensors to high-resolution models.

of detecting and inspecting up to 6,000 parts per minute all in an industrial IP67 enclosure small enough to fit into the tightest of spaces.

This provides extremely reliable part detection, unattainable with photoelectric sensors.

Checker Advantages Inspects features that other sensors cannot.

2 The Smart Vision Sensor Looking for the easiest, most affordable way to error-proof your manufacturing process? The original Checker vision sensor defined the category, taking the best attributes of photoelectric sensors and adding so much more for manufacturers and machine builders. Today, Checker has a complete product family spanning from lower-resolution, extremely fast sensors to high-resolution models. What Checker Is The Checker vision sensor is an award-winning, all-in-one vision sensor with built-in camera, processor, lighting, optics, and I/O capable of detecting and inspecting up to 6,000 parts per minute all in an industrial IP67 enclosure small enough to fit into the tightest of spaces. How Checker Works Checker detects a part by finding an actual part feature, such as the apple graphic on top of the juice boxes. This provides extremely reliable part detection, unattainable with photoelectric sensors. The optional SensorView display lets users see exactly what s being inspected, as well as production statistics. Checker Advantages Inspects features that other sensors cannot. Because Checker understands what it sees, it can inspect features that other sensors can t, such as a code printed on a label. Overcomes varying part positions. Parts on a line typically vary in position, and Checker tracks all of them without requiring precise part handling. Inspects multiple part features simultaneously. There s no limit to the number of part features you can inspect with a single Checker! 2 Checker Vision Sensors

The ROI of Vision Sensors Wouldn t it be great if you could use the same sensor for all your product verification tasks?

And now that Cognex offers a full range of vision sensors, including Ethernet connectivity, you have the opportunity to choose the right Checker for your application.

Checker 3G Series No PC required Solves both presence and measurement applications Configurable as either presence or measurement sensor Standard and high-resolution sensors available Patented part

Unlimited Image storage Remote setup and display PLC Communication with Ethernet Logic for custom outputs Up to 32 job changes Up to 4 discrete outputs A partial list of the benefits that a vision

Displaying and recording images Eliminating the need for costly fixturing Eliminating PLC programming 100% parts-inspection initiative CASE STUDY Checker Helps Automate High-Speed Loading of

3 The ROI of Vision Sensors Wouldn t it be great if you could use the same sensor for all your product verification tasks? The Checker product family has the ability to be used for Presence/Absence applications and/or for Measurement applications. Checker can perform multiple checks on each product you manufacture. And now that Cognex offers a full range of vision sensors, including Ethernet connectivity, you have the opportunity to choose the right Checker for your application. Whether it s price, resolution, or speed that is important to you, Cognex offers a sensor to fit your needs. Checker 3G Series No PC required Solves both presence and measurement applications Configurable as either presence or measurement sensor Standard and high-resolution sensors available Patented part detection technology Checker 4G Easy setup through your PC Patented part detection technology Solves both presence and measurement applications High Speed and High Resolution models available Unlimited Image storage Remote setup and display PLC Communication with Ethernet Logic for custom outputs Up to 32 job changes Up to 4 discrete outputs A partial list of the benefits that a vision sensor brings to a manufacturing operation include: Reducing scrap Reducing downtime and maintenance Providing easy setup and maintenance by factory personnel Simplifying the overall system design Displaying and recording images Eliminating the need for costly fixturing Eliminating PLC programming 100% parts-inspection initiative CASE STUDY Checker Helps Automate High-Speed Loading of Transparent Cartons A beverage manufacturer uses transparent cartons to package its bottled drinks so that their distinctive branded labels are visible to consumers. The need to orient the bottles so that the right part of the label is visible makes automated packaging a challenge. Recently, this producer became the first to successfully automate high-speed carton loading with the use of a bucket autoload cartoner, using Cognex Checker vision sensors. Because Checker vision sensors are so simple to set up and easy to install, they offer a very cost-effective solution for inspections where traditional sensors are not reliable and a full-blown vision system is too expensive. AFA Nordale, a leading producer of cartoner machines, evaluated several sensors from leading companies but each seemed to have problems with one or more label types. For example, one sensor worked with the red labels but not with the black or blue labels, said Sergiu Dinescu, from Nordale. Another sensor worked with the red and blue labels but not the black. Then we tried the Cognex Checker and found that it was able to read all the labels without difficulty. 3 Checker Vision Sensors

Reliable Error-Proofing for All Industries Verifying component thickness Automotive products Detecting missing bottles Consumer products

manufacturing costs Confirms required 12 bottles per case Replaces 13 photoelectric sensors No need for precise fixturing Improves

Electronics products Detecting missing caps and lot codes Beverage applications Checks SMT component orientation Reliable readings even

Confirms caps & codes on milk jugs Reliable readings even with variable jug positions Reduces scrap & maintenance costs Increases line

4 Reliable Error-Proofing for All Industries Verifying component thickness Automotive products Detecting missing bottles Consumer products Determines metal part thickness after machining No need for constant adjustment No need for precise fixturing Improves quality Reduces manufacturing costs Confirms required 12 bottles per case Replaces 13 photoelectric sensors No need for precise fixturing Improves quality & yield Increases line speed Correct Thickness Incorrect Thickness Case Full Bottle Missing Checking component orientation Electronics products Detecting missing caps and lot codes Beverage applications Checks SMT component orientation Reliable readings even with variable positions and sizes Reduces downtime by eliminating position adjustments & minimizing resets Maintains high line speeds Confirms caps & codes on milk jugs Reliable readings even with variable jug positions Reduces scrap & maintenance costs Increases line speed by elimination of fixturing Capacitor Oriented Correctly Capacitor Oriented Backwards Date Code Present Date Code Missing 4 Checker Vision Sensors

No Matter What Industry, Checker Delivers Verifying threads in hole Automotive

threads in engine block Outperforms eddy current probes Consistent accuracy vs.

ownership Detects caps & safety seals on bottles No need for precise fixturing

elimination of sensor adjustments Thread Present Thread Absent Safety Seal Present

presence Beverage applications Inspects for correct product number on medical

Decreases errors during faster line changeovers Checks presence of three labels on

Eliminates constant readjustment Drastically cuts changeover time Improves quality

5 No Matter What Industry, Checker Delivers Verifying threads in hole Automotive applications Verifying seal and cap presence Consumer products Detects presence of threads in engine block Outperforms eddy current probes Consistent accuracy vs. photoeyes Reliable, repeatable results No need for precise fixturing Lowers cost of ownership Detects caps & safety seals on bottles No need for precise fixturing Minimizes setup & changeover Improves output & decreases scrap Reduces downtime by elimination of sensor adjustments Thread Present Thread Absent Safety Seal Present Safety Seal Missing Matching device product number Medical products Verifying label presence Beverage applications Inspects for correct product number on medical devices Eliminates manual inspection Improves quality Drastically cuts rework costs Decreases errors during faster line changeovers Checks presence of three labels on beer bottle on high-speed (1100 bpm) line Replaces unsatisfactory photo sensor Eliminates constant readjustment Drastically cuts changeover time Improves quality Reduces manufacturing cost Correct Product Number Wrong Product Number Label Present Label Missing 5 Checker Vision Sensors

Reliable Inspection Results for Manufacturers Verifying part orientation Automotive

automotive parts in feeder bowl Much less expensive than traditional vision system

presence of pills in bottle Reliable readings even with variable bottle positions

quality Correct Orientation Wrong Orientation Pill Bottle Full Pill Bottle Empty

Consumer products Confirms presence and positioning of seals & bushings on

inspection part fixturing Increases quality & decreases return rates Enables faster

Eliminates material waste Flexible working distance For high-speed production lines.

6 Reliable Inspection Results for Manufacturers Verifying part orientation Automotive products Verifying pill presence Medical products Detects incorrect orientation of automotive parts in feeder bowl Much less expensive than traditional vision system Allows 100% correct orientation Dramatically reduces scrap & rework Detects presence of pills in bottle Reliable readings even with variable bottle positions Maintains high line speed without fixturing Minimizes inspection errors Improves quality Correct Orientation Wrong Orientation Pill Bottle Full Pill Bottle Empty Inspecting seal and bushing in battery Consumer products Verifying registration Consumer products Confirms presence and positioning of seals & bushings on batteries Reliable readings even with variable battery positions Eliminates inspection part fixturing Increases quality & decreases return rates Enables faster line speeds Pattern-based registration Eliminates the need for registration marks Eliminates material waste Flexible working distance For high-speed production lines... up to 6 m/sec Better than 100 µsec output repeatability Good Part Missing Bushing Mark Detected 6 Checker Vision Sensors

quality Drastically reduces rework costs Increases line speed Checks for correct-sized light bulb Replaces photoelectric sensors Allows fewer & smoother changeovers Improves

insert Food products Verifying slug ejection Consumer products Confirms flavor pack presence Reliable readings even with translucent insert & variable positions Cuts rework costs

7 and Machine Builders. Verifying device assembly Medical products Verifying correct bulb Consumer products Identifies dowel pins & plastic cover Replaces error-prone manual inspection Increases product quality Drastically reduces rework costs Increases line speed Checks for correct-sized light bulb Replaces photoelectric sensors Allows fewer & smoother changeovers Improves quality Reduces scrap costs Increases yields Minimizes customer complaints All Parts Present All Parts Missing Correct Size in Package Wrong Size in Package Detecting missing box insert Food products Verifying slug ejection Consumer products Confirms flavor pack presence Reliable readings even with translucent insert & variable positions Cuts rework costs Reduces downtime by elimination of sensor adjustments Detects plastic slug presence in bottle Eliminates multiple photoelectric sensors No expensive fixturing Reliable readings even with variable bottle positions Maintains line speed Handles colors without adjusting Insert Present Insert Missing Slug Ejected Slug Present 7 Checker Vision Sensors

Powerful Things Come in Small Packages Checker is an all-in-one vision sensor with built-in lighting and a variable working distance, capable

36in) Compact size User-changeable working distance and focus High intensity illumination enhances contrast (4G Series Shown) 67mm (2.

housing 41mm (1.61in) 39mm (1.54in) Checker 4G with Ethernet easily integrates into your factory network.

8 Powerful Things Come in Small Packages Checker is an all-in-one vision sensor with built-in lighting and a variable working distance, capable of inspecting over 6000 parts per minute all in a package small enough to fit into tight spaces. 60mm (2.36in) Compact size User-changeable working distance and focus High intensity illumination enhances contrast (4G Series Shown) 67mm (2.64in) IP67 quick-disconnect cables Industrial I/O User-configurable sink or source Ethernet (4G Series) Mini-USB (3G Series) Rugged IP67 housing 41mm (1.61in) 39mm (1.54in) Checker 4G with Ethernet easily integrates into your factory network. From one PC, you can remotely setup and monitor Checker(s) on your network, communicate to your PLC and FTP transfer an unlimited amount of images for storage and/or review. PC 4G PLC FTP Ethernet Network 8 Checker Vision Sensors

9 A Wide Range of Checker Cognex has expanded the Checker product family to ensure that we offer a sensor for every application. Whether it s resolution, price, or speed that is the most important attribute to you, Cognex offers it all. Vision System Vision Sensor Range Photoelectric Sensor Performance Model Features 3G1 3G7 4G1 4G7 Part Finding Sensor a a a a Inspection Sensors: Presence a a a a Inspection Sensors: Measurement a a a a Internal Triggering a a a a Pattern Retrain a a a a Job Change PC Software Setup a a a a SensorView Setup & Display a a Encoder-Based Part Tracking a a Logic for Custom Outputs a a Fast Inspection 800 ppm a a a a Ultrafast Inspection over 6000 ppm a a Highest Resolution (752 x 480) a a PLC Communication EtherNet/IP with AOP a a PLC communication - PROFINET a a Store images to FTP a a 9 Checker Vision Sensors

One-Click Setup Checker is simple to set up and operate with One-Click Setup. Even a first-time user can have it up and running in minutes without training.

10 One-Click Setup Checker is simple to set up and operate with One-Click Setup. Even a first-time user can have it up and running in minutes without training. Simply select the built-in part finding sensor place inspection sensors on the features to inspect then check it with Checker! The image display simplifies setup by enabling you to see what the sensor sees. Four simple steps walk you through setup. Dynamic help is always available. Simple sensor controls are pass/fail no data or parameters to enter. Play a filmstrip back in slow motion, or review recent part failures. Like a video recorder, Checker actually records video of parts! Checker s unique inspection sensors provide the most reliable way to inspect your part: Brightness sensors look for dark or light areas on the part. Contrast sensors look for areas on the part that contain both bright and dark areas: date codes, threads, and many other part features. Pattern sensors understand what your part features look like and let you know when the feature appears. Width sensors measure the width of a part, component, or feature. Height sensors measure the height of a part, component, or feature. Diameter sensors measure the diameter of a part, component, or feature. The Checker part finding sensor has three important advantages: 1. Detects a part by locating a feature on the part, not just an edge. 2. Tracks parts in varying positions along the production line, overcoming imprecise part positioning. 3. Does not require additional sensors to determine if a part is present. 10 Checker Vision Sensors

11 Specifications CHECKER VISION SENSORS Lighting 3G1 Integrated red, green, and cyan LEDs 3G7, 4G1, 4G7 Integrated bright white LEDs EXTERNAL TRIGGER INPUT Input ON > 10VDC (> 6mA) Input OFF < 2VDC (< 1.5mA) Protection Opto-isolated, polarityindependent OUTPUTS Output Rating Max voltage drop Max load Protection encoder inputs Encoder type ON/OFF Load Solid state switch 100mA, 24VDC 100mA 100mA Opto-isolated, protected from short circuit, overcurrent, and reverse polarity 300 khz (max) quadrature encoder. Open collector and differential output. 50% nominal 50% encoder maximum JOB CONTROL INPUTS Jobs supported 8 (3G Series) 32 (4G Series) minimum pulse width - 1 msec Input ON > 10VDC (> 6mA) Input OFF < 2VDC (< 1.5mA) Protection Opto-isolated, polarityindependent power Voltage Current +24VDC (22-26VDC) 250mA max ENVIRONMENTAL Operating temperature 0 to 50 C (32 to 122 F) Storage temperature -30 to 80 C (-22 to 176 F) Operating humidity 0%-90%, non-condensing Operating altitude 4000m maximum Shock 80Gs for 5ms on each axis (per IEC ) Vibration 10Gs (10-500Hz) per IEC Protection IP67 MECHANICAL Dimensions Weight 67mm (2.64in) H x 41mm (1.61in) W x 60mm (2.36in) D 148g (4.2oz) MODES OF OPERATION Internal part trigger, external part trigger, free running CERTIFICATIONS 3G Series 4G Series CE, ccsa us,fcc,rohs, KCC CE,FCC,RoHS,KCC and BureauVeritas minimum pc requirements (Only required for setup) Operating systems XP, Vista, Microsoft Windows 7 32&64 bit RAM 128 MB RAM Interface USB USB 1.1 (2.0 recommended (3G Series) for best performance) Interface Ethernet 10/100 (4G Series) Screen resolution 1024 x 768 (96 DPI) or 1280 x 1024 (120 DPI) display CHECKER SENSORS Model Part Number 4G1 C4G1-24G-E00 4G7 C4G7-24G-E00 3G1 C3G1-21G-U00 3G7 C3G7-24G-U00 Included accessories 5.8mm lens Checker software CD Standard USB cable 3G only Mounting screws Quick Start Guide Allen wrench (for focus lock) Optional Accessories C3G-CBL-001 Flying lead I/O cable (5m) CKR-200-CBL-RT-003 Right angle I/O cable (1m) CCB X-XX Ethernet Cable(s) CCB Right angle Ethernet Cable (5m) Field of View for Checker 3G7 and 4G7 Vision Sensors Curves show the field of view for standard and optional lenses. Each grid square = 1in (2.54cm) sensorview 350 Handheld programmer 3G Series only models supported User-selectable languages English, German, Italian, French, Spanish, Portuguese, Japanese, Chinese (Simplified), Chinese (Traditional), Korean Power Operating voltage Power consumption +24VDC (22-26VDC) +24VDC Environmental Operating temperature 0 C to 50 C (32 F to 122 ) Operating humidity 0 to 90%, non-condensing Storage temperature -20 C to 80 C (-4 F to 176 F) Storage humidity 0 to 90%, non-condensing Shock 80G x 5ms (IEC ) Vibration 10Gs (10-500Hz per IEC Altitude 4000m Protection IP65 CERTIFICATIONS CE, c CSA us, FCC, RoHS MODELS Part Number Description SV SensorView 350 panel-mount display Field of View for Checker 3G1 and 4G1 Vision Sensors Curves show the field of view for standard and optional lenses. Each grid square = 1in (2.54cm) 11 Checker Vision Sensors

Accessories SensorView Teach Pendant A compact, rugged, panel-mount display 3G series of vision sensors.

This enables operators to easily monitor their production process, change jobs, or retrain patterns without a PC.

It provides an easy way to adjust the mounting angle of Checker for optimal lighting.

6, 8, 16, and 25mm lenses. Colored Filters Bandpass filters for both visible and IR wavelengths (470, 525, 590, 635 and 850nm).

Corporate Headquarters One Vision Drive Natick, MA USA Tel: +1 508.650.

3344 Americas United States, East United States, West United States, South United States, Detroit United States, Chicago Canada Mexico Central America

2726 +52 81 5030-7258 +52 81 5030-7258 +1 972.365.

12 Accessories SensorView Teach Pendant A compact, rugged, panel-mount display 3G series of vision sensors. More than just a display, SensorView provides production statistics and a user-definable view of the parts that Checker is inspecting. This enables operators to easily monitor their production process, change jobs, or retrain patterns without a PC. Adjustable Mounting Bracket With metric, imperial, and through-hole mounting. It provides an easy way to adjust the mounting angle of Checker for optimal lighting. Cables Power & I/O, Ethernet and USB cables are available in straight and right angle. Lenses The Checker lens kit includes 3.6, 8, 16, and 25mm lenses. Colored Filters Bandpass filters for both visible and IR wavelengths (470, 525, 590, 635 and 850nm). Companies around the world rely on Cognex vision and ID to optimize quality, drive down costs and control traceability. Corporate Headquarters One Vision Drive Natick, MA USA Tel: Fax: Americas United States, East United States, West United States, South United States, Detroit United States, Chicago Canada Mexico Central America South America Brazil Europe Austria Belgium France Germany Hungary Ireland Italy Netherlands Spain Sweden Switzerland United Kingdom Asia China India Japan Korea Singapore Taiwan Copyright 2011, Cognex Corporation. All information in this document is subject to change without notice. Cognex, Checker and SensorView are registered trademarks of Cognex Corporation. All other trademarks are the property of their respective owners. Printed in the U.S.A. Lit. No. MK Checker Vision Sensors

C h e c k e r V i s i o n S e n s o r s

C h e c k e r V i s i o n S e n s o r s The Smart Vision Sensor Looking for the easiest, most affordable way to error-proof your manufacturing process? The original Checker vision sensor defined the category,